Initial development of high-accuracy CFRP panel for DATE5 antenna

Abstract

DATE5 antenna, which is a 5m telescope for terahertz exploration, will be sited at Dome A, Antarctica. It is necessary to keep high surface accuracy of the primary reflector panels so that high observing efficiency can be achieved. In antenna field, carbon fiber reinforced composite (CFRP) sandwich panels are widely used as these panels are light in weight, high in strength, low in thermal expansion, and cheap in mass fabrication. In DATE5 project, CFRP panels are important panel candidates. In the design study phase, a CFRP prototype panel of 1-meter size is initially developed for the verification purpose. This paper introduces the material arrangement in the sandwich panel, measured performance of this testing sandwich structure samples, and together with the panel forming process. For anti-icing in the South Pole region, a special CFRP heating film is embedded in the front skin of sandwich panel. The properties of some types of basic building materials are tested. Base on the results, the deformation of prototype panel with different sandwich structures and skin layers are simulated and a best structural concept is selected. The panel mold used is a high accuracy one with a surface rms error of 1.4 μm. Prototype panels are replicated from the mold. Room temperature curing resin is used to reduce the thermal deformation in the resin transfer process. In the curing, vacuum negative pressure technology is also used to increase the volume content of carbon fiber. After the measurement of the three coordinate measure machine (CMM), a prototype CFRP panel of 5.1 μm rms surface error is developed initially.